Garment-like absorbent article

ABSTRACT

A garment-like absorbent article includes an absorbent chassis that defines a waist opening and first and second leg openings. A longitudinal length of the chassis is optimized in a linear relationship with the waist circumference of the chassis, the circumference measured at 500 grams tension. With respect to the linear relationship, the thickness of the garment is substantially constant along the same line defined by the length and the circumference, and decreases as the y-intercept increases.

BACKGROUND OF THE INVENTION

[0001] This invention is directed to a pant-like article that functionsand feels like underwear, and also includes absorbent properties.

[0002] Pant-like absorbent garments, such as training pants, aredesigned as a transitional garment to assist a wearer in the transitionfrom diapers to underwear during a toilet training process. Ideally,training pants should resemble underwear in terms of fit and comfort,while providing absorbent properties to catch any “accidents” that mayoccur while the wearer is wearing the garment. Unlike underwear,training pants can be bulky due to the volume of absorbent materialcontained therein. This bulkiness can make the garment feel more like adiaper than like underwear. Similarly, other types of pant-likeabsorbent garments, such as adult incontinence garments, swimwear, anddiapers, include absorbent materials and, as a result, may seem bulky.

[0003] From a manufacturing point of view, it is desirable to include aslittle material as possible in each garment to generate cost savings interms of material expenditures. From a consumer's point of view, it isdesirable to include as much material as necessary to provide acomfortable fit as well as adequate absorbency and leak resistance.Thus, it is desirable to optimize the amount of material used in suchgarments by determining the least amount of material necessary toprovide sufficient comfort and functionality.

[0004] Absorbent garments are typically constructed of multiple layers,with an absorbent layer positioned between an outer cover and a bodyside liner, for example. Additional layers, each having specializedfunctions, may also be included in the structure of absorbent garments,including, but not limited to, surge layers, spacer layers, and barrierlayers. Each of these layers adds to the overall thickness of thegarment, with the absorbent layer typically being the thickest layer ofall. Generally, the thicker the garment, the longer the garment must beto envelop all of the intermediate layers, thus adding to themanufacturing cost of the garment.

[0005] There is thus a need or desire for an absorbent pant-like garmenthaving optimized physical parameters, resulting in a garment that looksand feels like underwear. There is a further need or desire for anabsorbent pant-like garment having an optimized length relative to thewaist circumference of the garment with an optimized thickness, whilemaintaining a considerable level of flexibility and absorbent capacity.

SUMMARY OF THE INVENTION

[0006] In response to the discussed difficulties and problemsencountered in the prior art, a new pant-like absorbent garment havingoptimized parameters has been discovered. The principles of the presentinvention may be applied to any of a number of personal care productapplications, such as training pants, diapers, diaper pants, swimwear,adult incontinence products, and the like.

[0007] The pant-like absorbent garment of the invention includes anabsorbent chassis that defines a waist opening and first and second legopenings. The longitudinal length of the garment is measured from afront waist edge of the chassis to a back waist edge of the chassis. Thecircumference of the waist opening is measured, for the purposes of thepresent invention, at 500 grams tension. In this invention, the lengthis optimized in a linear relationship with the waist circumference andthe thickness of the garment. More particularly, the longitudinal lengthis proportional to the circumference of the waist opening according tothe following linear relationship:

Length<(Circumference−b)/m,

[0008] where b is the y-intercept and m is the slope of the line. Evenmore particularly, it has been found that in the linear relationship ofthe garment of the invention, the slope (m) is 1.6 and the y-intercept(b) can be −99, or −114, or −128, depending on the maximum length ormaximum thickness desired.

[0009] The thickness is substantially constant along the same linedefined by the length and the circumference, and decreases as they-intercept increases. Suitably, the thickness of the garment is lessthan about 4.5 millimeters, or less than about 4 mm, or less than about3 mm, or less than about 2 mm. The length is between about 350 and about650 millimeters, and the circumference is between about 450 and about750 millimeters. Furthermore, the garment also has a considerable levelof flexibility, and has an absorbent capacity of between about 100 andabout 800 grams.

[0010] With the foregoing in mind, it is a feature and advantage of theinvention to provide a pant-like absorbent garment having optimizedparameters set forth in a linear relationship between the longitudinallength, waist circumference, and thickness of the garment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is a perspective view of a pant-like absorbent garment,such as a training pant, having the optimized parameters of theinvention;

[0012]FIG. 2 is a perspective view of a pant-like absorbent garment withrefastenable side seams, having the optimized parameters of theinvention;

[0013]FIG. 3 is a plan view of the absorbent garment of FIG. 1 in apartially disassembled, stretched flat state, and showing the surface ofthe garment that faces away from the wearer when the garment is worn,according to one embodiment of this invention;

[0014]FIG. 4 is a plan view of the absorbent garment of FIG. 2 in apartially disassembled, stretched flat state, and showing the surface ofthe garment that faces the wearer when the article is worn, and withportions cut away to show the underlying features, according to oneembodiment of this invention;

[0015]FIG. 5 is a cross-sectional view of the absorbent garment of FIG.1 taken along line 5-5;

[0016]FIG. 6 is a cross-sectional view of a representational prior artabsorbent garment from a view similar to the view of the garment in FIG.5;

[0017]FIG. 7 is a graphical representation of the optimized parametersof several embodiments of the invention;

[0018]FIG. 8 is a graphical representation of the optimized parametersof one embodiment of the invention with a number of test codes imposedthereon;

[0019]FIG. 9 is a graphical representation of the optimized parametersof another embodiment of the invention with a number of test codesimposed thereon;

[0020]FIG. 10 is a graphical representation of the optimized parametersof yet another embodiment of the invention with a number of test codesimposed thereon;

[0021]FIG. 11 illustrates a pant of the type shown in FIG. 1 disposed ona tensile tester to measure waist circumference;

[0022]FIG. 12 illustrates a side view of a tensile tester used tomeasure waist circumference, as shown in FIG. 11;

[0023]FIG. 13 representatively shows a partially cut away top view of asaturated capacity tester;

[0024]FIG. 14 representatively shows a side view of a saturated capacitytester; and

[0025]FIG. 15 representatively shows a rear view of a saturated capacitytester.

DEFINITIONS

[0026] Within the context of this specification, each term or phrasebelow will include the following meaning or meanings.

[0027] “Absorbent article” includes personal care garments, medicalgarments, and the like. The term “disposable garment” includes garmentswhich are typically disposed of after 1-5 uses. The term “personal caregarment” includes diapers, diaper pants, training pants, swim wear,absorbent underpants, adult incontinence products, feminine hygieneproducts, and the like.

[0028] “Attached” refers to the joining, adhering, connecting, bonding,or the like, of at least two elements. Two elements will be consideredto be attached together when they are attached directly to one anotheror indirectly to one another, such as when each is directly attached tointermediate elements.

[0029] “Coform” refers to a material produced by combining separatepolymer and additive streams into a single deposition stream in forminga nonwoven web. Such a process is taught, for example, by U.S. Pat. No.4,100,324 to Anderson et al. which is hereby incorporated by reference.

[0030] “Layer” when used in the singular can have the dual meaning of asingle element or a plurality of elements.

[0031] “Longitudinal” and “transverse” have their customary meaning, asindicated by the longitudinal and transverse axes depicted in FIGS. 3and 4. The longitudinal axis lies in the plane of the article and isgenerally parallel to a vertical plane that bisects a standing wearerinto left and right body halves when the article is worn. The transverseaxis lies in the plane of the article generally perpendicular to thelongitudinal axis. The article as illustrated is longer in thelongitudinal direction than in the transverse direction.

[0032] “Meltblown fiber” refers to fibers formed by extruding a moltenthermoplastic material through a plurality of fine, usually circular,die capillaries as molten threads or filaments into converging highvelocity gas (e.g., air) streams which attenuate the filaments of moltenthermoplastic material to reduce their diameter, which may be tomicrofiber diameter. Thereafter, the meltblown fibers are carried by thehigh velocity gas stream and are deposited on a collecting surface toform a web of randomly dispersed meltblown fibers. Such processes areknown in the art. Meltblown fibers are microfibers which may becontinuous or discontinuous, are generally smaller than about 0.6denier, and are generally self bonding when deposited onto a collectingsurface.

[0033] “Nonwoven” and “nonwoven web” refer to materials and webs ofmaterial having a structure of individual fibers or filaments which areinterlaid, but not in an identifiable manner as in a knitted fabric. Theterms “fiber” and “filament” are used herein interchangeably. Nonwovenfabrics or webs have been formed from many processes such as, forexample, meltblowing processes, spunbonding processes, air layingprocesses, and bonded carded web processes. The basis weight of nonwovenfabrics is usually expressed in ounces of material per square yard (osy)or grams per square meter (gsm) and the fiber diameters are usuallyexpressed in microns. (Note that to convert from osy to gsm, multiplyosy by 33.91.)

[0034] “Polymers” include, but are not limited to, homopolymers,copolymers, such as for example, block, graft, random and alternatingcopolymers, terpolymers, etc. and blends and modifications thereof.Furthermore, unless otherwise specifically limited, the term “polymer”shall include all possible geometrical configurations of the material.These configurations include, but are not limited to isotactic,syndiotactic and atactic symmetries.

[0035] “Spunbond fiber” refers to small diameter fibers which are formedby extruding molten thermoplastic material as filaments from a pluralityof fine capillaries of a spinnerette having a circular or otherconfiguration, with the diameter of the extruded filaments then beingrapidly reduced, as known in the art. Spunbond fibers are quenched andgenerally not tacky when they are deposited onto a collecting surface.Spunbond fibers are generally continuous and often have average denierslarger than about 0.3, more particularly, between about 0.6 and 10.

[0036] “Superabsorbent,” “superabsorbent polymer,” or “superabsorbentmaterial” refers to a water-swellable, water-insoluble organic orinorganic material capable, under the most favorable conditions, ofabsorbing at least about 15 times its weight and, more desirably, atleast about 30 times its weight in an aqueous solution containing 0.9weight percent sodium chloride. The superabsorbent materials can benatural, synthetic and modified natural polymers and materials. Inaddition, the superabsorbent materials can be inorganic materials, suchas silica gels, or organic compounds such as cross-linked polymers.

[0037] These terms may be defined with additional language in theremaining portions of the specification.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0038] The present invention is directed to a pant-like absorbentgarment having optimized parameters. More particularly, a longitudinallength of the garment is proportional to a waist circumference of thegarment according to a linear relationship. Furthermore, with respect tothe length and circumference linear relationship, the thicknessparameter of the garment is substantially constant along the same linedefined by the length and circumference relationship, and decreases asthe y-intercept increases.

[0039] The principles of the present invention can be incorporated intoany suitable pant-like disposable absorbent article. Examples of suchsuitable articles include diapers, diaper pants, training pants,incontinence products, other personal care or health care garments,including medical garments, or the like. As used herein, the term“incontinence products” includes absorbent underwear for children,absorbent garments for children or young adults with special needs suchas autistic children or others with bladder/bowel control problems as aresult of physical disabilities, as well as absorbent garments forincontinent older adults. For ease of explanation, the descriptionhereafter will be in terms of a child's training pant.

[0040] The term “training pant,” as used herein, refers to a pant-styleabsorbent garment having either permanently bonded side seams orrefastenable side seams that are packaged and sold in a pre-fastened,ready-to-wear position. In other words, the training pant is providedwith a continuous waist circumference when the garment is delivered tothe consumer with any pre-determined fastening determined by themanufacturer. Thus, the training pant has an automatic fit, as opposedto an adjustable fit, with a pertinent waist circumference determined bythe manufacturer such that the training pant is packaged by themanufacturer in a user-friendly mode wherein a wearer can put thegarment on without having to manually adjust any fastening devices.

[0041] Referring to FIG. 1, a pant-like absorbent article, such as atraining pant 20, is illustrated. The training pant 20 includes achassis 32 defining a front region 22, a back region 24, and a crotchregion 26 interconnecting the front and back regions. The chassis 32includes a body side liner 42 which is configured to contact the wearer,and an outer cover 40 opposite the body side liner which is configuredto contact the wearer's clothing. An absorbent assembly 44 (FIG. 4) ispositioned or located between the outer cover 40 and the body side liner42.

[0042]FIG. 2 illustrates a training pant 20, similar to the trainingpant 20 illustrated in FIG. 1 but having refastenable sides. A trainingpant 20 having permanently bonded sides, as shown in FIG. 1, or atraining pant 20 having refastenable sides in the fastened position, aspartially shown in FIG. 2, defines a three-dimensional pantconfiguration having a waist opening 50 and a pair of leg openings 52.The front region 22 includes the portion of the training pant 20 which,when worn, is positioned on the front of the wearer while the backregion 24 includes the portion of the training pant which, when worm, ispositioned on the back of the wearer. The crotch region 26 of thetraining pant 20 includes the portion of the training pant which, whenworn, is positioned between the legs of the wearer and covers the lowertorso of the wearer.

[0043] As shown in further detail in FIGS. 3 and 4, the chassis 32 alsodefines a pair of longitudinally opposed waist edges, which aredesignated front waist edge 38 and back waist edge 39. The front region22 is contiguous with the front waist edge 38, and the back region 24 iscontiguous with the back waist edge 39. The waist edges 38, 39 areconfigured to encircle the waist of the wearer when worn and provide thewaist opening 50 which defines the waist circumference dimension, asdescribed below. For reference, arrows 48 and 49 depicting theorientation of the longitudinal axis and the transverse axis,respectively, of the training pant 20 are illustrated in FIGS. 3 and 4.

[0044] The illustrated absorbent chassis 32 includes a pair oftransversely opposed front side panels 34, and a pair of transverselyopposed back side panels 234. The side panels 34, 234 may be integrallyformed with the outer cover 40 and/or the body side liner 42, or mayinclude two or more separate elements.

[0045] In particular embodiments for improved fit and appearance, theside panels 34 and 234 desirably have an average length dimensionmeasured parallel to the longitudinal axis 48 that is about 20 percentor greater, and particularly about 25 percent or greater, of the overalllength dimension of the absorbent article, also measured parallel to thelongitudinal axis 48. For example, in training pants having an overalllength dimension of about 54 centimeters, the side panels 34 and 234desirably have an average length dimension of about 10 centimeters orgreater, such as about 15 centimeters. While each of the side panels 34and 234 extend from the waist opening 50 to one of the leg openings 52,the back side panels 234 have a continually decreasing length dimensionmoving in an outward transverse direction, as is best shown in FIGS. 3and 4.

[0046] The side panels 34 and 234 desirably include an elastic materialcapable of stretching in a direction generally parallel to thetransverse axis 49 of the training pant 20. Suitable elastic materials,as well as processes of incorporating side panels into a training pant,are known to those skilled in the art, and are described, for example,in U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel et al.,which is incorporated herein by reference.

[0047] As mentioned, the training pant 20 according to the presentinvention may be refastenable, thereby including a fastening system 80for securing the training pant about the waist of the wearer (FIG. 2).The illustrated fastening system 80 may include fastening components 82that are adapted to refastenably connect to mating fastening components84. In one embodiment, one surface of each of the fastening components82 and 84 includes a plurality of engaging elements that project fromthat surface. The engaging elements of these fastening components 82 areadapted to repeatedly engage and disengage the engaging elements of themating fastening components 84.

[0048] In one particular embodiment, the fastening components 82 eachinclude hook type fasteners and the mating fastening components 84 eachinclude complementary loop type fasteners. In another particularembodiment, the fastening components 82 each include loop type fastenersand the mating fastening components 84 each include complementary hooktype fasteners.

[0049] Loop type fasteners typically include a fabric or material havinga base or backing structure and a plurality of loop members extendingupwardly from at least one surface of the backing structure. The loopmaterial can be formed of any suitable material, such as acrylic, nylonor polyester, and can be formed by methods such as warp knitting, stitchbonding or needle punching. Suitable loop materials are available fromGuilford Mills, Inc., Greensboro, N.C., U.S.A. In one embodiment, theouter cover material and/or the body side liner material may serve as aloop type fastener.

[0050] Hook type fasteners typically include a fabric or material havinga base or backing structure and a plurality of hook members extendingupwardly from at least one surface of the backing structure. Suitablesingle-sided hook materials for the fastening components 82 or themating fastening components 84 are available from Velcro IndustriesB.V., Amsterdam, Netherlands or affiliates thereof. In one embodiment,the outer cover material and/or the body side liner material may serveas a hook type fastener.

[0051] The absorbent assembly 44 can be any structure which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids and certain body wastes atthe levels discussed herein. The absorbent assembly 44 can bemanufactured in a wide variety of sizes and shapes, and from a widevariety of liquid absorbent materials commonly used in the art. Forexample, the absorbent assembly 44 can suitably include a matrix ofhydrophilic fibers, such as a web of cellulosic fluff, mixed withparticles of a high-absorbency material commonly known as superabsorbentmaterial. In a particular embodiment, the absorbent assembly 44 includesa matrix of cellulosic fluff, such as wood pulp fluff, andsuperabsorbent hydrogel-forming particles. The wood pulp fluff can beexchanged with synthetic, polymeric, meltblown fibers or with acombination of meltblown fibers and natural fibers. The superabsorbentparticles can be substantially homogeneously mixed with the hydrophilicfibers or can be nonuniformly mixed. The fluff and superabsorbentparticles can also be selectively placed into desired zones of theabsorbent assembly 44 to better contain and absorb body exudates. Theabsorbent assembly 44 can have variable thickness, with greaterthickness in “target” areas, such as in a central portion of the crotchregion. The concentration of the superabsorbent particles can also varythrough the thickness of the absorbent assembly 44. Alternatively, theabsorbent assembly 44 can include a laminate of fibrous webs andsuperabsorbent material or other suitable means of maintaining asuperabsorbent material in a localized area.

[0052] Suitable superabsorbent materials can be selected from natural,synthetic, and modified natural polymers and materials. Thesuperabsorbent materials can be inorganic materials, such as silicagels, or organic compounds, such as crosslinked polymers. Suitablesuperabsorbent materials are available from various commercial vendors,such as Dow Chemical Company located in Midland, Mich., U.S.A., andStockhausen GmbH & Co. KG, D-47805 Krefeld, Federal Republic of Germany.Typically, a superabsorbent material is capable of absorbing at leastabout 15 times its weight in water, and desirably is capable ofabsorbing more than about 25 times its weight in water.

[0053] In one embodiment, the absorbent assembly 44 can include anextremely thin absorbent composite material sold under the trade nameNOVATHIN® available from Rayonier Corporation located in Jessup, Ga.,U.S.A., and/or an ultra-thin-absorbent (UTA) material including amixture of SAP and pulp fiber. An example of a suitable UTA may include3.7 grams (g) of FAVOR® SXM 9543 SAP, available from Stockhausen GmbH &Co. KG located in Krefeld, Fed. Rep. of Germany, and 3.7 g of NB416 pulpfiber available from Weyerhauser located in Federal Way.

[0054] In another embodiment, the absorbent assembly 44 can be generallyrectangular in shape, and can include a blend of wood pulp fluff andsuperabsorbent material. One preferred type of fluff is identified withthe trade designation CR1654, available from U.S. Alliance,Childersburg, Ala., U.S.A., and is a bleached, highly absorbent sulfatewood pulp containing primarily soft wood fibers. As a general rule, thesuperabsorbent material is present in the absorbent assembly 44 in anamount of from about 0 to about 90 weight percent based on total weightof the absorbent assembly 44. The absorbent assembly 44 suitably has adensity within the range of about 0.10 to about 0.50 grams per cubiccentimeter. The absorbent assembly 44 may or may not be wrapped orencompassed by a suitable tissue wrap that maintains the integrityand/or shape of the absorbent assembly 44.

[0055] The chassis 32 can also incorporate other materials that aredesigned primarily to receive, temporarily store, and/or transportliquid along the mutually facing surface with the absorbent assembly 44,thereby maximizing the overall absorbent capacity of the absorbentassembly 44, if desired. One suitable material is referred to as a surgelayer The absorbent assembly 44, typically the most bulky component of atraining pant 20, is relatively thin in the present invention. As aresult, the overall thickness of the garment of the present invention,as measured according to the test method below, is less than about 4.5millimeters (mm), or less than about 4 mm, or less than about 3 mm, orless than about 2 mm. Because the overall thickness of the garment isrelatively small, the garment can possess the look and feel ofunderwear. Furthermore, due to the minimal bulkiness of the garment, theoverall longitudinal length of the garment, measured from the frontwaist edge 38 to the back waist edge 39 as described in further detailin the test method below, can be shorter than bulkier garments whilemaintaining the same position and fit as bulkier garments. For example,most pant-like garments are worn with the front waist edge 38 resting inthe area of the wearer's navel and the back waist edge 39 resting alongthe small of the wearer's back. Both a bulky garment and the garment ofthe invention can be worn in the same manner, stretching from thewearer's navel to the small of the wearer's back, while the bulkygarment has a longitudinal length considerably larger than thelongitudinal length of the garment of the invention.

[0056]FIG. 5 is a cross-sectional view of the garment 20 of FIG. 1,showing the thin absorbent layer 44 between the outer cover 40 and thebody side liner 42. As can be seen in FIG. 5, very little excess lengthis added to the outer cover 40 and to the body side liner 42 to envelopthe absorbent layer 44. In contrast, FIG. 6 shows a representationalprior art absorbent garment 86 from the same view as in FIG. 5, in whichit is apparent that the outer cover 40 and the body side liner 42 mustbe longer in the prior art garment 86 than in the garment 20 in order toencompass the thick absorbent layer 44 while covering the same length ofthe wearer's body as the garment 20 of the invention covers.

[0057] Training pants and other pant-like absorbent garments aretypically marketed in sizes that correspond to an intended wearer'sweight. For purposes of describing the garment 20 of the presentinvention in terms of size independent of the intended wearer, thegarment size is described in terms of the circumference of the waistopening 50. A method for determining the waist circumference (at 500grams tension) is described in detail below. In the garment 20 of thepresent invention, the circumference of the waist opening 50 may be in arange of between about 450 mm and about 750 mm, or between about 500 mmand about 700 mm.

[0058] The garment 20 of the invention has been configured in a mannerthat provides desirable product features and the resulting product hasbeen found to have a certain relationship between the longitudinallength and the waist circumference. More specifically, the garment 20 ofthe invention has a longitudinal length of the absorbent chassis 32 thatis proportional to the waist circumference of the chassis 32 in a linearrelationship that does not hold true for currently available commercialtraining pants. The longitudinal length of the training pant 20 can bemeasured according to the method described in detail below. In thegarment 20 of the present invention, the longitudinal length of thegarment may be in a range of between about 350 mm and about 650 mm, orbetween about 375 mm and about 600 mm, or between about 400 mm and about575 mm.

[0059] As illustrated in FIG. 7, a linear relationship can be drawnbetween the longitudinal length (x) and the waist circumference (y) inaccordance with the well-known equation of a line:

y=m×+b  (1)

[0060] wherein m is the slope of the line and b is the y-intercept ofthe line. Isolating the longitudinal length variable, the equationbecomes:

Length=(Circumference−b)/m  (2)

[0061] Equation 2 is used to determine the maximum length of thegarments of the invention. Thus, the equation is more accurately writtenas:

Length<(Circumference−b)/m  (3)

[0062] As represented in Equation 3, the range of length andcircumference relationships exists above the line.

[0063] In each of the embodiments of the invention, the slope (m) isapproximately 1.6. In one embodiment of the invention, the y-interceptis −128, resulting in the following equation:

Length<(Circumference+128)/1.6  (4)

[0064] In another embodiment of the invention having a lower maximumlength, the y-intercept is −114, resulting in the following equation:

Length<(Circumference+114)/1.6  (5)

[0065] In another embodiment of the invention having an even lowermaximum length, the y-intercept is −99, resulting in the followingequation:

Length<(Circumference+99)/1.6  (6)

[0066] The relationship between length, circumference, and thickness isa three-dimensional relationship, but can be approximated in atwo-dimensional form with the thickness dimension superimposed over thelinear relationship between length and circumference. As a result, shownin FIG. 7, the thickness is substantially constant along each of thelines defining the length and the circumference parameters, anddecreases as the y-intercept increases. However, because the thicknessis superimposed from a three-dimensional state onto the two-dimensionalgraph, the lines, in addition to representing the length/circumferencerelationship, represent shadows of the thickness parameters rather thanactual thickness parameters. Thus, in FIGS. 8-10 in the Example below,the labels of approximate thicknesses are merely approximations andcannot be represented precisely in a two-dimensional form.

[0067] Equations 3-6 can be used in a process for making the garment 20of the invention. More particularly, once a desired waist circumferencehas been determined, the circumference can be substituted into Equation3, along with a desired slope (m) and y-intercept (b), to determine anappropriate longitudinal length of the garment. Equations 4-7 providesuggested slope and y-intercept values, namely a slope of 1.6 and ay-intercept of −128, −114, or −99. Once the desired longitudinal lengthhas been determined, the garment 20 can be made.

[0068] The garment 20 of the invention suitably has a saturated capacityof between about 100 and about 800 grams, or between about 150 and about600 grams, or between about 200 and about 500 grams. The saturatedcapacity of the garment can be measured according to the test methoddescribed in detail below.

[0069] The garment 20 of the invention suitably has an edge compressionpeak load of less than about 1500 grams, or less than about 1200 grams,or less than about 800 grams. The edge compression peak load of thegarment can be measured according to the test method described in detailbelow.

[0070] The outer cover 40 desirably includes a material that issubstantially liquid impermeable, and can be elastic, stretchable ornonstretchable. The outer cover 40 can be a single layer of liquidimpermeable material, but desirably includes a multi-layered laminatestructure in which at least one of the layers is liquid impermeable. Forinstance, the outer cover 40 can include a liquid permeable outer layerand a liquid impermeable inner layer that are suitably joined togetherby a laminate adhesive (not shown). Suitable laminate adhesives, whichcan be applied continuously or intermittently as beads, a spray,parallel swirls, or the like, can be obtained from Findley Adhesives,Inc., of Wauwatosa, Wis., U.S.A., or from National Starch and ChemicalCompany, Bridgewater, N.J., U.S.A. The liquid permeable outer layer canbe any suitable material and desirably one that provides a generallycloth-like texture. One example of such a material is a 20 gsm (gramsper square meter) spunbond polypropylene nonwoven web. The outer layermay also be made of those materials of which liquid permeable body sideliner 42 is made. While it is not a necessity for the outer layer to beliquid permeable, it is desired that it provides a relatively cloth-liketexture to the wearer.

[0071] The inner layer of the outer cover 40 can be both liquid andvapor impermeable, or can be liquid impermeable and vapor permeable. Theinner layer is desirably manufactured from a thin plastic film, althoughother flexible liquid impermeable materials may also be used. The innerlayer, or the liquid impermeable outer cover 40 when a single layer,prevents waste material from wetting articles, such as bedsheets andclothing, as well as the wearer and care giver. A suitable liquidimpermeable film for use as a liquid impermeable inner layer, or asingle layer liquid impermeable outer cover 40, is a 0.2 millimeterpolyethylene film commercially available from Huntsman Packaging ofNewport News, Va., U.S.A. If the outer cover 40 is a single layer ofmaterial, it can be embossed and/or matte finished to provide a morecloth-like appearance. As earlier mentioned, the liquid impermeablematerial can permit vapors to escape from the interior of the disposableabsorbent article, while still preventing liquids from passing throughthe outer cover 40. A suitable “breathable” material is composed of amicroporous polymer film or a nonwoven fabric that has been coated orotherwise treated to impart a desired level of liquid impermeability. Asuitable microporous film is a PMP-1 film material commerciallyavailable from Mitsui Toatsu Chemicals, Inc., Tokyo, Japan, or anXKO-8044 polyolefin film commercially available from 3M Company,Minneapolis, Minn.

[0072] Certain “non-breathable” elastic films can also be used to makethe outer cover 40. Examples of suitable non-breathable films can bemade of styrene-ethylene-butylene-styrene or styrene-isoprene-styreneblock copolymers, KRATON polymers from Kraton Polymers USLLC of Belpre,Ohio, U.S.A., metallocene catalyzed elastomers or plastomers, and thelike. Other materials suitable for making the outer cover 40 includemonolithic breathable films, such as those made of polyether amide basedpolymers, for example PEBAX, and ether/ester polyurethanethermal-plastic elastomers.

[0073] The liquid permeable body side liner 42 is illustrated asoverlying the outer cover 40 and absorbent assembly 44, and may but neednot have the same dimensions as the outer cover 40. The body side liner42 is desirably compliant, soft feeling, and non-irritating to thewearer's skin. Further, the body side liner 42 can be less hydrophilicthan the absorbent assembly 44, to present a relatively dry surface tothe wearer and permit liquid to readily penetrate through its thickness.

[0074] The body side liner 42 can be manufactured from a wide selectionof web materials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Various wovenand nonwoven fabrics can be used for the body side liner 42. Forexample, the body side liner can be composed of a meltblown orspunbonded web of polyolefin fibers. The body side liner can also be abonded-carded web composed of natural and/or synthetic fibers. The bodyside liner can be composed of a substantially hydrophobic material, andthe hydrophobic material can, optionally, be treated with a surfactantor otherwise processed to impart a desired level of wettability andhydrophilicity. For example, the material can be surface treated withabout 0.45 weight percent of a surfactant mixture including AHCOVEL®N-62 available from available from Uniqema Inc., a division of ICI ofNew Castle, Del., U.S.A. and GLUCOPON® 220UP available from CognisCorporation of Ambler, Pa., and produced in Cincinnati, Ohio, in anactive ratio of 3:1. The surfactant can be applied by any conventionalmeans, such as spraying, printing, brush coating or the like. Thesurfactant can be applied to the entire body side liner 42 or can beselectively applied to particular sections of the body side liner, suchas the medial section along the longitudinal centerline.

[0075] A suitable liquid permeable body side liner 42 is a nonwovenbicomponent web having a basis weight of about 27 gsm. The nonwovenbicomponent can be a spunbond bicomponent web, or a bonded cardedbicomponent web. Suitable bicomponent staple fibers include apolyethylene/polypropylene bicomponent fiber available from CHISSOCorporation, Osaka, Japan. In this particular bicomponent fiber, thepolypropylene forms the core and the polyethylene forms the sheath ofthe fiber. Other fiber orientations are possible, such as multi-lobe,side-by-side, end-to-end, or the like. While the outer cover 40 and bodyside liner 42 can include elastomeric materials, it can be desirable insome embodiments for the composite structure to be generally inelastic,where the outer cover, the body side liner and the absorbent assemblyinclude materials that are generally not elastomeric.

[0076] To further enhance containment and/or absorption of bodyexudates, the training pant 20 may include a front waist elastic member54, a rear waist elastic member 56, and leg elastic members 58, as areknown to those skilled in the art (FIG. 4). The waist elastic members 54and 56 can be operatively joined to the outer cover 40 and/or body sideliner 42 along the opposite waist edges 38 and 39, and can extend overpart or all of the waist edges. The leg elastic members 58 are desirablyoperatively joined to the outer cover 40 and/or body side liner 42 alongopposite side edges of the chassis 32 and positioned in the crotchregion 26 of the training pant 20.

[0077] The waist elastic members 54, 56 and the leg elastic members 58can be formed of any suitable elastic material. As is well known tothose skilled in the art, suitable elastic materials include sheets,strands or ribbons of natural rubber, synthetic rubber, or thermoplasticelastomeric polymers. The elastic materials can be stretched and adheredto a substrate, adhered to a gathered substrate, or adhered to asubstrate and then elasticized or shrunk, for example with theapplication of heat; such that elastic constrictive forces are impartedto the substrate. In one particular embodiment, for example, the legelastic members 58 include a plurality of dry-spun coalescedmultifilament spandex elastomeric threads sold under the trade nameLYCRA® and available from E. I. DuPont de Nemours and Company,Wilmington, Del., U.S.A.

[0078] To enhance containment and/or absorption of any body exudatesdischarged from the wearer, the chassis 32 may include a pair ofcontainment flaps 46 which are configured to provide a barrier to thetransverse flow of body exudates. A flap elastic member 53 (FIG. 4) maybe operatively joined with each containment flap 46 in any suitablemanner as is well known in the art. The elasticized containment flaps 46define an unattached edge which assumes an upright, generallyperpendicular configuration in at least the crotch region 26 of thetraining pant 20 to form a seal against the wearer's body. Thecontainment flaps 46 can be located along the transversely opposed sideedges of the chassis 32, and can extend longitudinally along the entirelength of the chassis or may only extend partially along the length ofthe chassis. Suitable constructions and arrangements for the containmentflaps 46 are generally well known to those skilled in the art.

[0079] As described herein, the various components of the absorbentgarment 20 can be integrally assembled together employing various typesof suitable attachment means, such as adhesive, sonic and thermal bondsor combinations thereof. The resulting product is a thin, flexible,disposable, absorbent garment that fits just like underwear. Moreparticularly, the absorbent garment has a maximum length proportional toa maximum thickness relative to a waist circumference of the garment,while maintaining a considerable absorbent capacity.

EXAMPLE

[0080] The following Example provides a comparison between trainingpants having optimized parameters in accordance with the presentinvention and presently available commercial products. Morespecifically, this example provides a graphical representation of thetraining pants of the invention and of presently available commercialproducts with respect to the linear relationship that defines thetraining pants of the present invention.

[0081] Table 1 provides descriptions of the training pants tested inthis Example, with codes 17-22 being experimental codes. Codes 17 and20-22 are representative of the training pants of the present invention.TABLE 1 Training Pants Tested Product Location Date Code Name SizeGender Manufacturer Purchased Purchased 1 TARGET ® M Unisex Paragon USASeptember training 2000 pants 2 TARGET ® L Unisex Paragon USA Septembertraining 2000 pants 3 EASY-UPS ® M Unisex Procter & USA March Gamble2002 4 EASY-UPS ® L Unisex Procter & USA March Gamble 2002 5 EASY-UPS ®XL Unisex Procter & USA March Gamble 2002 6 Libero Up & Maxi Unisex SCAHolland June 2001 Go 7 Libero Up & Maxi+ Unisex SCA Holland June 2001 Go8 Libero Up & XL Unisex SCA Holland June 2001 Go 9 Libero Up & XL+Unisex SCA Holland June 2001 Go 10 Mooney M Boy Uni Charm Japan AugustMan 2000 11 Mooney L Boy Uni Charm Japan August Man 2000 12 Mooney XLGirl Uni Charm Japan August Man 2000 13 Torepan Girl Uni Charm JapanAugust Man 2000 14 PULL-UPS ® M Unisex Kimberly- USA January Clark 200215 PULL-UPS ® L Unisex Kimberly- USA January Clark 2002 16 PULL-UPS ® XLUnisex Kimberly- USA January Clark 2002 17 Experimental M UnisexKimberly- A Clark 18 Experimental L Unisex Kimberly- B Clark 19Experimental XL Unisex Kimberly- C Clark 20 Experimental L-XL UnisexKimberly- D Clark 21 Experimental L-XL Unisex Kimberly- E Clark 22Experimental L-XL Unisex Kimberly F Clark

[0082] Experimental codes A, B, and C (codes 17-19) each included thesame composition and design with the only differences being the sizes.More particularly, these codes were made up of the same components as aPULL-UPS® training pant, but with ultra-thin absorbent layers in placeof the original absorbent layers. These ultra-thin absorbent layers aretaught in U.S. patent application Ser. No. 09/939,061 filed Aug. 24,2001, herein incorporated by reference. More specifically, Experimentalcode A (code 17) included an ultra-thin absorbent made up of 12.0 gFAVOR 9543 superabsorbent material, available from Stockhausen GmbH &Co., and 9.8 g ND416 pulp, available from Weyerhaeuser of Federal Way,Washington, U.S.A., Experimental code B (code 18) included an ultra thinabsorbent made up of 12.9 g FAVOR 9543 superabsorbent material and 10.5g ND416 pulp, and Experimental code C (code 19) included an ultra thinabsorbent made up of 13.5 g FAVOR 9543 superabsorbent material and 11.1g ND416 pulp.

[0083] Experimental code D (code 20) was a refastenable training pantwith all-around stretch. The pant had an outer cover made up of amonolithic breathable film laminated between two 0.3 osy polypropylenespunbond facings that were necked and creped, and a body side liner madeup of necked and creped polypropylene spunbond. Between the outer coverand the body side liner was a 450 gsm absorbent layer made up of acoformed material of 10% KRATON 2760 meltblown filament available fromKraton Polymers, 15% Sulfitate HJ pulp available from RayonierCorporation of Jessup, Ga., U.S.A, and 75% FAVOR 880 superabsorbentmaterial available from Stockhausen GmbH & Co. The pant also includedcontainment flaps, waist elastic, leg elastics, and fasteners, all inaccordance with the described invention.

[0084] Experimental code E (code 21) was a non-refastenable trainingpant having an outer cover made up of the same components as a PULL-UPS®training pant, but with an ultra-thin absorbent layer in place of theoriginal absorbent layer, similar to the ultra-thin absorbent layers incodes 17-19, including 3.9 g FAVOR 9543 superabsorbent material and 3.9g ND416 pulp and having a basis weight of 225 gsm.

[0085] Experimental code F (code 22) was a non-refastenable trainingpant, similiar to code E (code 21), but having a 29.5 g 400 gsm NOVATHINComposite 4000160 absorbent layer, available from Rayonier, in amaximized area.

[0086] Each of the training pants listed in Table 1 were tested forlongitudinal length, front thickness, waist circumference, and saturatedcapacity, in accordance with each of the test methods provided below.Each of the tests were performed on five samples of each product, andthe averages of the results are provided in Table 2. TABLE 2 Parametersof the Training Pants Listed in Table 1 Waist Saturated Length ThicknessCircumference Capacity Code (mm) (mm) at 500 g (mm) (g/g) 1 457 6.66 543384 2 486 8.42 544 498 3 450 10.09 539 508 4 466 10.55 556 533 5 4929.27 599 620 6 427 6.31 514 516 7 450 6.38 575 520 8 483 7.16 577 668 9484 7.56 582 725 10 421 6.24 527 416 11 462 6.01 566 468 12 500 5.36 614577 13 458 4.13 542 130 14 459 6.85 580 440 15 505 6.81 626 546 16 5166.85 686 517 17 441 4.39 575 388 18 486 4.76 613 396 19 515 4.41 679 44320 467 3.37 649 684 21 461 2.44 668 154 22 474 1.57 673 479

[0087] The data from Table 2 is provided in FIG. 8, with the line acrossthe graph and the area above the line representing the embodiment of theinvention in which the longitudinal length is proportional to thecircumference of the waist opening according to the relation:

Length<(Circumference+128)/1.6

[0088] As indicated in FIG. 8, the thickness of the garments along theline is approximately 4 mm, with the garments in the area above the linehaving even smaller thicknesses.

[0089] Similarly, the data from Table 2 is also provided in FIG. 9, withthe line across the graph and the area above the line representing theembodiment of the invention in which the longitudinal length isproportional to the circumference of the waist opening according to therelation:

Length<(Circumference+114)/1.6

[0090] As indicated in FIG. 9, the thickness of the garments along theline is approximately 3 mm.

[0091] The data from Table 2 is also provided in FIG. 10, with the lineacross the graph and the area above the line representing the embodimentof the invention in which the longitudinal length is proportional to thecircumference of the waist opening according to the relation:

Length<(Circumference+99)/1.6

[0092] As indicated in FIG. 10, the thickness of the garments along theline is approximately 2 mm.

Test Methods Thickness Measurement Test Method

[0093] A whole absorbent product can be measured for thickness in thethickest part of the product, usually in the target zone that isintended to receive liquid insults. When measured by the methoddescribed below, such a product suitably may have a dry thickness(t_(i)) of less than about 4.5 mm, more suitably less than about 4.0 mm,even more suitably less than about 3.0 mm, most suitably less than about2.0 mm. For example, in one embodiment of this invention, the absorbentgarment may have a dry thickness of about 0.5 to about 3.0 mm.

[0094] If the sample exhibits greatest thickness in the target region ofthe product, the sample can be tested in this location by the followingmethod. Samples with greater thickness outside the target region shouldbe tested in the location of greatest thickness.

[0095] The sample to be tested is folded in half as for wearing, withfront and back waist edges aligned. The liner of the product is markedat the fold line. The product is opened and laid flat, and the frontregion of the absorbent is marked halfway between the marked fold andthe front edge of the absorbent, along the longitudinal centerline ofthe product. If the product is closed (such as with side seams), theseams are opened so that the product can be laid flat. Elastics (such asalong leg borders or in containment flaps) are removed if possible, orcut in several places to permit the absorbent to lie flat in anuncontracted state.

[0096] The sample is tested for dry thickness at the marked point on thefront of the absorbent, forward of the marked fold line. The intactproduct is gently spread flat to remove any wrinkles at this location,but is not stretched.

[0097] The product is placed underneath a 0.2 pounds per square inch(psi) weight, and the thickness of the product in this region isrecorded. A suitable tester for absorbent thickness is a MITUTOYO 543Series thickness gauge, available from Mitutoyo-MTI Corporation, Japan,equipped with a 3 inch diameter brass foot that applies a weight of 0.2psi. Five specimens per sample are tested, and the results are averagedto provide a thickness value for that sample.

Longitudinal Length Measurement Test Method

[0098] The product (20) has a length dimension measured between thefront and back end edges (38 and 39) along the longitudinal axis (48).The length dimension of the product (20) is determined.

[0099] A suitable method for determining the longitudinal length of theproduct (20) is to hang the product vertically adjacent a flat, verticalsurface. Prior to hanging, the product is opened by cutting or openingany side seams. Any elastic components that run the length of thechassis (such as leg elastics or elastics within containment flaps) aresevered at least once per inch along their entire length. The product ishung with the back region (24) above the front region (22) and with thesurface intended to face the wearer's outer garments during usepositioned toward the flat, vertical surface. The top end margin of theproduct is held horizontal with two clamps, the inner edges of which arespaced 3.5 inches (8.9 cm) apart. The clamps are positioned if possibleto avoid any absorbent within the product, and are symmetricallydisposed with respect to the longitudinal centerline/axis of theproduct. Any waist elastic present in the product is not stretched priorto securing the clamps.

[0100] The lower end of the hanging product (front waistband region) isclamped with a jig weighing 250 g. The jig possesses two clamp units(medium size, Bulldog clips, 2⅛ inch) attached to a tie rod(¼-inch-20×12 inches, coarse thread, zinc plated), the clampssymmetrically placed with respect to the longitudinal centerline of theproduct, with a spacing between internal edges of the clamps of 3.5inches (8.9 cm), with a ¼-inch nut placed at the inner and outer edgesof each clamp to hold the clamps in place. One (capped) bottle (1-ounceplastic screw cap bottle, such as NALGENE brand) is attached to eachclamp with a piece of string. The assembly is placed on a laboratorybalance and lead shot (No. 5 chilled lead shot, such as LAWRENCE brand)is added to each bottle (in equal amounts) until the total weight of thejig is as close to 250 grams as possible. The jig is attached to thelower end of the hanging product, as mentioned above.

[0101] For a typical product, a load of 250 g is appropriate. Theelongate length is then determined by measuring the distance between thefront and back end edges (38 and 39) along the longitudinalcenterline/axis (48), between the clamps. Five specimens of each codeare analyzed, and the results for each code are averaged.

Waist Circumference Measurement Test Method

[0102] This procedure is a single-cycle tension bench test to measurewaistband circumference of a test pant. The pant is tested in the statein which it is provided to the consumer, intended for immediate donning.The procedure measures waistband circumference under moderate tensionafter the waistband has been subjected to higher tension. A test pant iscycled to a specific loading rather than to a fixedelongation/extension.

[0103] Data generated by this test method includes:

[0104] Waistband circumference (mm) at an initial load of 70 g.

[0105] Waistband circumference (mm) at an intermediate load of 2000 g.

[0106] Waistband circumference (mm) at a final load of 500 g.

[0107] 1. Overview

[0108] A pant is placed on the upper and lower pins in position tomeasure the waistband gage length, as shown in FIG. 11. Each pin isinserted one inch (2.5 cm) into the waist section of the pant. If thepant slips on the pins, clips may be applied to hold the pant firmly inplace on the pins; care should be taken to avoid placing clips ontoparts of the waistband that do not pass over the pins. The gage lengthis selected for the waist opening of the pant being tested, so as toprovide a tension of between 0 and 65 grams (g) when the pant ispositioned for the test, prior to the start of the test. The term“tension” refers to the gram value measured by the load cells in thetensile tester.

[0109] The jaws are separated until a load of 70 grams of tension isattained, at which tension the gage length is recorded. Then the jawscontinue to move apart until 2,000 grams of tension is reached, at whichtension the gage length is again recorded. The jaws then moveimmediately back together until a tension of 500 grams is reached, atwhich tension the gage length is again recorded. The standard test isone cycle per pant. The circumference at a given tension may becalculated using the gage length and the circumference value(s) for theupper and lower pins. Desirably at least five specimens are tested. Thewaistband circumference values at 500 grams tension from each specimentested are averaged to obtain an average waistband circumference for agiven sample.

[0110]FIG. 12 illustrates a side view of a tensile tester used tomeasure waistband circumferences of pants according to the presentinvention. FIG. 11 illustrates a pant of the type shown in FIG. 1disposed on the tensile tester to measure the waistband circumference.

[0111] 2. Apparatus and Materials

[0112] 2.1 Constant Rate of Extension (CRE) tensile tester: MTS tensiletester model Synergie 200 Test Bed; available from MTS® SystemsCorporation, Research Triangle Park, N.C. USA.

[0113] 2.2 Load cells: A suitable cell selected so the majority of thepeak load values fall between the manufacturer's recommended ranges ofload cell's full scale value; Model 100N available from MTS® SystemsCorporation, Research Triangle Park, N.C. USA.

[0114] 2.3 Operating software and data acquisition system: MTSTestWorks® for Windows software version 4.06A, build 617; available fromMTS® Systems Corporation, Research Triangle Park, N.C. USA.

[0115] 2.4 Grips: pneumatic-action grips, top and bottom, identified aspart number 2712-003 available from Instron Corporation, Canton, Mass.USA.

[0116] 2.5 Grip faces: 25 by 75-mm (1 by 3-inch), suitable for holdingpins.

[0117] 2.6 Pins: rigid pins having a length of 6.3 centimeters (2.5inch) and a knurled portion at one end for holding specimens, theknurled portion having an outside diameter of 6.4 millimeters (0.25inch) and a length of 3.2 centimeters (1.25 inch).

[0118] 2.7 Clips (optional): 1.9 cm. wide by 0.95 cm. capacity (¾″ wideby ⅜″ capacity) binder clips; part no. BTMOO251 available from BT OfficeProducts, Milwaukee, Wis., USA.

[0119] 3. Conditioning

[0120] Conduct test in standard ASTM laboratory conditions: atmosphereof 23±2° C. (73.4±3.6° F.) and 50±5% relative humidity. The productsshould be measured after they equilibrate to laboratory conditions.

[0121] 4. Test Specimen

[0122] No preparation needed. The whole pant is tested.

[0123] 5. Procedure

[0124] Tensile Tester test conditions: Data acquisition rate 100.0 HzPerform PreLoad (PreCond)? No Perform PreConditioning? No PerformPreLoad? No Cross head speed: 500 mm/min Gage length: Appropriatestarting gage length settings for both hip and waistband are those thatwill generate initial loads of between 0 and 65 g in a previouslyuntested product Go to load (cycle trigger): 2000 g (or a maximum loadvalue that can be experienced by the sample without causing the sampleto tear or otherwise come apart) Number of cycles: 1 Break sensitivity:90%

[0125] A. Install pin assemblies as depicted in FIG. 11.

[0126] B. Using the tensile frame pushbutton controls for crossheadposition, move pins so that the pant can be mounted on the pins withoutstretching the pant. Determine the gage length by measuring from thecenterline of the first pin to the centerline of the second pin.Calibrate the software to this initial gage length.

[0127] C. Place the waistband onto the knurled section of the top pin.Center one side of the pant on top of the pin. Use a single binder clipto hold the pant at the waist opening in place on the pin; do notstretch the pant during application of the clip.

[0128] D. Click on ZERO to tare the load of the pant. Only tare theweight of the first pant for each sample population, not for eachspecimen.

[0129] E. Place the waistband on the opposite side of the pant on thebottom pin and clip in place as for the first pin. Adjust pant so bothtop and bottom pins are inserted 2.5 centimeters (1 inch) into the pant.

[0130] F. Using the tensile frame pushbutton controls for crossheadposition, move pins apart until the load applied to the waistband isbetween 0 and 65 g.

[0131] G. Click on RUN button. The test will start automatically.

[0132] H. When the test is done, click on either FILE to save the dataand graphs or NEXT to save only the data.

[0133] I. Remove the sample from the pins.

[0134] J. Repeat steps B, C and E through I for each specimen until thetesting is complete.

[0135] The circumference of a measured waistband at any tension may becalculated by multiplying the gage length at that tension by 2, andadding one half the circumference of the upper pin and one half thecircumference of the lower pin.

Modified Saturated Capacity Test Method

[0136] Saturated Capacity is determined using a Saturated Capacity (SATCAP) tester with a Magnahelic vacuum gage and a latex dam. Referring toFIGS. 13-15, a Saturated Capacity tester vacuum apparatus 110 comprisesa vacuum chamber 112 supported on four leg members 114. The vacuumchamber 112 includes a front wall member 116, a rear wall member 118 andtwo side walls 120 and 121. The wall members are about 0.5 inch thick,and are constructed and arranged to provide a chamber having outsidedimensions measuring 23.5 inches in length, 14 inches in width and 8inches in depth.

[0137] A vacuum pump (not shown) operably connects with the vacuumchamber 112 through an appropriate vacuum line conduit and a vacuumvalve 124. In addition, a suitable air bleed line connects into thevacuum chamber 112 through an air bleed valve 126. A hanger assembly 128is suitably mounted on the rear wall 118 and is configured with S-curvedends to provide a convenient resting place for supporting a latex damsheet 130 in a convenient position away from the top of the vacuumapparatus 110. A suitable hanger assembly can be constructed from 0.25inch diameter stainless steel rod. The latex sheet 130 is looped arounda dowel member 132 to facilitate grasping and to allow a convenientmovement and positioning of the latex sheet 130. In the illustratedposition, the dowel member 132 is shown supported in a hanger assembly128 to position the latex sheet 130 in an open position away from thetop of the vacuum chamber 112.

[0138] A bottom edge of the latex sheet 130 is clamped against a rearedge support member 134 with suitable securing means, such as toggleclamps 140. The toggle clamps are mounted on the rear wall member 118with suitable spacers 141 which provide an appropriate orientation andalignment of the toggle clamps 140 for the desired operation. Threesupport shafts 142 are 0.75 inches in diameter and are removably mountedwithin the vacuum chamber 112 by means of support brackets 144. Thesupport brackets 144 are generally equally spaced along the front wallmember 116 and the rear wall member 118 and arranged in cooperatingpairs. In addition, the support brackets 144 are constructed andarranged to suitably position the uppermost portions of the supportshafts 142 flush with the top of the front, rear and side wall membersof the vacuum chamber 112. Thus, the support shafts 142 are positionedsubstantially parallel with one another and are generally aligned withthe side wall members 120 and 121. In addition to the rear edge supportmember 134, the apparatus 110 includes a front support member 136 andtwo side support members 138 and 139. Each side support member measuresabout 1 inch in width and about 1.25 inches in height. The lengths ofthe support members are constructed to suitably surround the peripheryof the open top edges of the vacuum chamber 112, and are positioned toprotrude above the top edges of the chamber wall members by a distanceof about 0.5 inch.

[0139] A layer of egg crating type material 146 is positioned on top ofthe support shafts 142 and the top edges of the wall members of thevacuum chamber 112. For example, the egg crating type material can be atranslucent light diffuser panel available from McMaster Supply CatalogNo. 162 4K 14, having a 13 mm by 13 mm opening in the panel. The eggcrating type material extends over a generally rectangular areameasuring 23.5 inches by 14 inches, and has a depth measurement of about0.38 inches. The individual cells of the egg crating structure measureabout 0.5 inch square, and the thin sheet material comprising the eggcrating is composed of a suitable material, such as polystyrene. A layerof 0.19 mesh nylon screening 148, which measures 23.5 inches by 14inches, is placed on top of egg crating material 146. Desirably, themesh nylon screening is a TEFLON-coated, 6 mm mesh nylon screeningavailable from Eagle Supply & Plastic, Inc., Part No. 7308.

[0140] A suitable drain line and a drain valve 150 connect to bottomplate member 119 of the vacuum chamber 112 to provide a convenientmechanism for draining liquids from the vacuum chamber 112. The variouswall members and support members of tester apparatus 110 may be composedof a suitable noncorroding, moisture-resistant material, such aspolycarbonate plastic. The various assembly joints may be affixed bysolvent welding, and the finished assembly of the tester is constructedto be watertight. A vacuum gauge 152 operably connects through a conduitinto the vacuum chamber 112. A suitable pressure gauge is a Magnahelicdifferential gauge capable of measuring a vacuum of 0-100 inches ofwater, such as a No. 2100 gauge available from Dwyer InstrumentIncorporated.

[0141] The dry product or other absorbent structure is weighed and thenplaced in an excess amount of 0.9% saline solution and allowed to soakfor 20 minutes. After the 20 minute soak time, the absorbent structureis placed on the egg crate material and mesh nylon screening of theSaturated Capacity tester. The latex sheet is placed over the absorbentstructure(s) and the entire egg crate grid so that the latex sheetcreates a seal when a vacuum is drawn on the tester. A vacuum of 0.5pounds per square inch (psi) is held in the Saturated Capacity testerfor five minutes. The vacuum creates a pressure on the absorbentstructure(s), causing drainage of some liquid. After five minutes at 0.5psi vacuum, the latex sheet is rolled back and the absorbentstructure(s) are weighed to generate a wet weight.

[0142] The overall capacity of each absorbent structure is determined bysubtracting the dry weight of each absorbent from the wet weight of thatabsorbent determined at this point in the procedure. The 0.5 psi SAT CAPor SAT CAP of the absorbent structure is determined by the followingformula:

SAT CAP=(wet weight−dry weight)/dry weight;

[0143] wherein the SAT CAP value has units of grams fluid/gramabsorbent. For both overall capacity and SAT CAP, a minimum of threespecimens of each sample should be tested and the results averaged. Ifthe absorbent structure has low integrity or disintegrates during thesoak or transfer procedures, the absorbent structure can be wrapped in acontainment material such as paper toweling, for example Hi-Dri® papertowels manufactured by Kimberly-Clark Corporation, Neenah, Wis., U.S.A.The absorbent structure can be tested with the overwrap in place and thecapacity of the overwrap can be independently determined and subtractedfrom the wet weight of the total wrapped absorbent structure to obtain awet absorbent weight.

Edge Compression Test Method

[0144] The method by which the Edge-wise Compression (EC) value can bedetermined is set forth below. A 2-inch by 12-inch (5.1 cm by 30.5 cm)piece of the absorbent article including the thickest part of theproduct is cut with its longer dimension aligned with the longitudinaldirection of the product or raw material web. The weight of the sampleis determined. The thickness of the material is determined under a 0.2psi (1.38 KPa) load. The material is formed into a cylinder having aheight of 2 inches (5.1 cm), and with the two ends having 0-0.125 inch(0-3.18 mm) overlap, the material is stapled together with threestaples. One staple is near the middle of the width of the product, theother two nearer each edge of the width of the material. The longestdimension of the staple is in the circumference of the formed cylinderto minimize the effect of the staples on the testing.

[0145] An INSTRON tester, or similar instrument, is configured with abottom platform, a platen larger than the circumference of the sample tobe tested and parallel to the bottom platform, attached to a compressionload cell placed in the inverted position. The specimen is placed on theplatform, under the platen. The platen is brought into contact with thespecimen and compresses the sample at a rate of 25 mm/min. The maximumforce obtained in compressing the sample to 50% of its width (1 inch)(2.54 cm) is recorded.

[0146] If the material buckles, it is typical for the maximum force tobe reached before the sample is compressed to 50%. In a product wherethe length of the absorbent is less than 12 inches (30.5 cm), the ECvalue of the material can be determined in the following manner. Adetailed discussion of the edge-wise compression strength has been givenin The Handbook Of Physical And Mechanical Testing Of Paper AndPaperboard, Richard E. Mark editor, Dekker 1983 (Vol. 1). Based ontheoretical models governing buckling stresses, in the Edge-wiseCompression configuration described, the buckling stress is proportionalto E*t²/(H²) with the proportionality constant being a function ofH²/(R*t) where E is the Elastic modulus, H is the height of thecylinder, R is the radius of the cylinder, and t is the thickness of thematerial. Expressing the stress in terms of force per basis weight, itcan be shown that the parameter that needs to be maintained constant isH²/R. Therefore, for a sample that is smaller than 12 inches (30.5 cm),the largest possible circle should be constructed and its height (widthof the sample being cut out) adjusted such that H²/R equals 2.1 inches(5.3 cm).

[0147] It will be appreciated that details of the foregoing embodiments,given for purposes of illustration, are not to be construed as limitingthe scope of this invention. Although only a few exemplary embodimentsof this invention have been described in detail above, those skilled inthe art will readily appreciate that many modifications are possible inthe exemplary embodiments without materially departing from the novelteachings and advantages of this invention. Accordingly, all suchmodifications are intended to be included within the scope of thisinvention, which is defined in the following claims and all equivalentsthereto. Further, it is recognized that many embodiments may beconceived that do not achieve all of the advantages of some embodiments,particularly of the preferred embodiments, yet the absence of aparticular advantage shall not be construed to necessarily mean thatsuch an embodiment is outside the scope of the present invention.

We claim:
 1. A pant-like absorbent garment, comprising: an absorbentchassis defining a waist opening and first and second leg openings; theabsorbent chassis having a longitudinal length and the waist openinghaving a circumference, such that the longitudinal length isproportional to the circumference of the waist opening according to therelation: Length≦(Circumference+128)/1.6, wherein the circumference ofthe waist opening is measured at 500 grams tension.
 2. The garment ofclaim 1, wherein the garment has a thickness of less than about 4.5millimeters.
 3. The garment of claim 1, wherein the garment has athickness of less than about 4 millimeters.
 4. The garment of claim 1,wherein the garment has a thickness of less than about 3 millimeters. 5.The garment of claim 1, wherein the garment has a thickness of less thanabout 2 millimeters.
 6. The garment of claim 1, wherein thecircumference of the waist opening is between about 450 and about 750millimeters.
 7. The garment of claim 1, wherein the circumference of thewaist opening is between about 500 and about 700 millimeters.
 8. Thegarment of claim 1, wherein the garment has a saturated capacity ofbetween about 100 and about 800 grams.
 9. The garment of claim 1,wherein the garment has a saturated capacity of between about 150 andabout 600 grams.
 10. The garment of claim 1, wherein the garment has asaturated capacity of between about 200 and about 500 grams.
 11. Thegarment of claim 1, wherein the garment has an edge compression peakload of less than about 1500 grams.
 12. The garment of claim 1, whereinthe garment has an edge compression peak load of less than about 1200grams.
 13. The garment of claim 1, wherein the garment has an edgecompression peak load of less than about 800 grams.
 14. A training pantcomprising the garment of claim
 1. 15. A pant-like absorbent garment,comprising: an absorbent chassis defining a waist opening and first andsecond leg openings; the absorbent chassis having a longitudinal lengthand the waist opening having a circumference, such that the longitudinallength is proportional to the circumference of the waist openingaccording to the relation: Length≦(Circumference+114)/1.6, wherein thecircumference of the waist opening is measured at 500 grams tension. 16.The garment of claim 15, wherein the garment has a thickness of lessthan about 4.5 millimeters.
 17. The garment of claim 15, wherein thegarment has a thickness of less than about 4 millimeters.
 18. Thegarment of claim 15, wherein the garment has a thickness of less thanabout 3 millimeters.
 19. The garment of claim 15, wherein the garmenthas a thickness of less than about 2 millimeters.
 20. The garment ofclaim 15, wherein the circumference of the waist opening is betweenabout 450 and about 750 millimeters.
 21. The garment of claim 15,wherein the circumference of the waist opening is between about 500 andabout 700 millimeters.
 22. The garment of claim 15, wherein the garmenthas a saturated capacity of between about 100 and about 800 grams. 23.The garment of claim 15, wherein the garment has a saturated capacity ofbetween about 150 and about 600 grams.
 24. The garment of claim 15,wherein the garment has a saturated capacity of between about 200 andabout 500 grams.
 25. The garment of claim 15, wherein the garment has anedge compression peak load of less than about 1500 grams.
 26. Thegarment of claim 15, wherein the garment has an edge compression peakload of less than about 1200 grams.
 27. The garment of claim 15, whereinthe garment has an edge compression peak load of less than about 800grams.
 28. A training pant comprising the garment of claim
 15. 29. Apant-like absorbent garment, comprising: an absorbent chassis defining awaist opening and first and second leg openings; the absorbent chassishaving a longitudinal length and the waist opening having acircumference, such that the longitudinal length is proportional to thecircumference of the waist opening according to the relation:Length≦(Circumference+99)/1.6, wherein the circumference of the waistopening is measured at 500 grams tension.
 30. The garment of claim 29,wherein the garment has a thickness of less than about 4.5 millimeters.31. The garment of claim 29, wherein the garment has a thickness of lessthan about 4 millimeters.
 32. The garment of claim 29, wherein thegarment has a thickness of less than about 3 millimeters.
 33. Thegarment of claim 29, wherein the garment has a thickness of less thanabout 2 millimeters.
 34. The garment of claim 29, wherein thecircumference of the waist opening is between about 450 and about 750millimeters.
 35. The garment of claim 29, wherein the circumference ofthe waist opening is between about 500 and about 700 millimeters. 36.The garment of claim 29, wherein the garment has a saturated capacity ofbetween about 1100 and about 800 grams.
 37. The garment of claim 29,wherein the garment has a saturated capacity of between about 150 andabout 600 grams.
 38. The garment of claim 29, wherein the garment has asaturated capacity of between about 200 and about 500 grams.
 39. Thegarment of claim 29, wherein the garment has an edge compression peakload of less than about 1500 grams.
 40. The garment of claim 29, whereinthe garment has an edge compression peak load of less than about 1200grams.
 41. The garment of claim 29, wherein the garment has an edgecompression peak load of less than about 800 grams.
 42. A training pantcomprising the garment of claim
 29. 43. A process for making a pant-likeabsorbent garment, comprising: determining a desired waist circumferencefor the absorbent garment, measured at 500 grams tension; determining adesired longitudinal length of the absorbent garment from the followingequation: Length≦(Circumference−b)/m; and making an absorbent garmenthaving a longitudinal length determined from the equation.
 44. Theprocess of claim 43, wherein m=1.6.
 45. The process of claim 43, whereinb=−128.
 46. The process of claim 43, wherein b=−114.
 47. The process ofclaim 43, wherein X=−99.